Mitsubishi Electric DLP WD-82CB1 User manual

MITSUBISHI ELECTRIC VISUAL SOLUTIONS AMERICA, INC.

9351 Jeronimo Road, Irvine, CA 92618-1904

CAUTION:

Before servicing this chassis, it is important that the service person read the "SAFETY PRECAUTIONS" and

"PRODUCT SAFETY NOTICE" contained in this manual.

DLP PROJECTION HDTV

SPECIFICATIONS

• Power Input : AC 120V, 60Hz

• Light Engine : DLP™ (1080p)

• Light Source : VIP Lamp

• Antenna Input : RF 75unbalanced

• Tuning : NTSC/ATSC/QAM

: Analog Cable - 1~125

Digital Cable - 1~135

• Speakers : 10W x 2 (except V45++)

: 2W x 16 (V45++)

• Analog Input

: Composite/Component

Level (RCA Type)

Y/Video: 1.0 Vp-p, Cr, Cb: 700mVp-p

75 unbalanced

: AUDIO IN JACK (RCA Type)

-4.7dBm 43k unbalanced

• Analog Output : AUDIO / SUBWOOFER OUT JACK

Level (RCA Type)

-4.7dBm 4.7kunbalanced

• Digital : AC-3/PCM Digital Audio Output

Inputs/Outputs (RCA Type)

: HDMI™

:

USB

: PC - use HMDI™

:

Wired IR Input/Output (V45++)

: Ethernet (V45CB, V45+, V45++)

: Bluetooth (V45++)

Manual

Service

• See Page 5 for additional specifications.

• Design specifications are subject to change without notice.

V45C

V45 V45CA

WD-73C11 WD-73640 WD-73CA1

V45+

V45++ V45CB

WD-73740 WD-73840 WD-82CB1

WD-82740

WD-82840

WD-92840

Version 3.0 10/13/11

2011

Page 3

MODELS: WD-73640 / WD-73740 / WD-73840 / WD-73C11 / WD-73CA1 /

WD-82740 / WD-82840 / WD-82CB1 / WD-92840

Version 3.0

CONTENTS

INTRODUCTION .................................................................................................................................. 5

Dimensions, weight, power usage, etc. ............................................................................................ 5

PRODUCT SAFETY NOTICE .............................................................................................................. 5

SAFETY PRECAUTIONS .................................................................................................................... 6

DISASSEMBLY & PARTS REPLACEMENT ...................................................................................... 7

Back Cover Removal ........................................................................................................................ 7

Chassis Removal ............................................................................................................................ 8

Rear Terminal Cover Removal ......................................................................................................... 8

PWB-POWER Removal ................................................................................................................... 9

PWB-MAIN Removal ........................................................................................................................ 9

PWB-BALLAST Removal ............................................................................................................... 10

Optical Engine Assembly Removal & Disassembly ....................................................................... 10

Optical Engine Replacement .......................................................................................................... 13

Projection Lens Replacement ........................................................................................................ 14

Color Wheel Replacement ............................................................................................................. 15

Screen Replacement ...................................................................................................................... 16

Mirror Replacement ........................................................................................................................ 20

SERVICE PROCEDURES ................................................................................................................. 23

Remote Control .............................................................................................................................. 23

Option Menu ................................................................................................................................... 24

Reset and Initialization ................................................................................................................... 26

LED Indications & Self Diagnostics ................................................................................................ 27

Error Codes .................................................................................................................................... 28

Error Code Log ............................................................................................................................... 28

Sound Projector Transducer Test .................................................................................................. 29

Service Adjustments

....................................................................................................................... 30

Equipment & Test Signals ..................................................................................................... 30

Service Menu ........................................................................................................................ 30

Horizontal & Vertical Position Adjustment ............................................................................. 31

Index Delay Adjustment ........................................................................................................ 31

Manual Geometry Alignment ................................................................................................. 32

Data Transfer Functions ................................................................................................................. 36

Using Lead Free Solder ................................................................................................................. 37

Chip Parts Replacement ................................................................................................................ 38

REPLACEMENT PARTS ................................................................................................................... 39

Safety Critical Parts Designation .................................................................................................... 39

Fuse Replacement Warning ........................................................................................................... 39

Parts Quick Reference ................................................................................................................... 40

Service Parts List ........................................................................................................................... 41

Screen Parts ................................................................................................................................... 46

Mirror Kits & Preparation ................................................................................................................ 48

CIRCUIT BLOCK DIAGRAMS .......................................................................................................... 50

SCHEMATIC DIAGRAMS ................................................................................................................. 56

Page 4

MODELS: WD-73640 / WD-73740 / WD-73840 / WD-73C11 / WD-73CA1 /

WD-82740 / WD-82840 / WD-82CB1 / WD-92840

Version 3.0

Digital Light Processing®, Digital Micro Mirror Device and DLP® are Trademarks of Texas Instruments.

HDMI, the HDMI logo and High-Definition Multimedia Interface are trademarks or registered trademarks of HDMI Licensing, LLC..

Page 5

MODELS: WD-73640 / WD-73740 / WD-73840 / WD-73C11 / WD-73CA1 /

WD-82740 / WD-82840 / WD-82CB1 / WD-92840

Version 3.0

INTRODUCTION

This service manual provides service instructions for the V45C, V45, V45CA, V45+, V45CB and V45++ chassis

types. The specific models for each chassis type, dimensions and weight are listed below. Service personnel should

read this manual thoroughly before servicing these chassis.

This service manual includes:

1. Disassembly & replacement instructions for cabinet and chassis components.

2. Replacing the Lenticular Screen, Fresnel Lens and Mirror.

3. Initial setup and troubleshooting.

4. Service adjustments.

5. Using lead free solder.

6. Chip parts replacement procedures.

7. Replacement part Instructions

8. Replacement parts list

9. Circuit block diagrams

10. Schematic diagrams

PRODUCT SAFETY NOTICE

Many electrical and mechanical parts in television receivers have special safety related characteristics. These char-

acteristics are often not evident from visual inspection nor can the protection afforded by them necessarily be ob-

tained by using replacement components rated for higher voltage, wattage, etc.

Replacement parts which have special safety characteristics are identified on the schematic diagrams and parts list

of this service manual. The replacement for any safety critical part should be identical in value and character-

istics.

The PWBs used in this chassis are constructed using Lead-Free Solder. When servicing use

only recommended Lead-Free Solder. Refer to the section “Using Lead Free Solder.”

MODEL CHASSIS HEIGHT WIDTH DEPTH WEIGHT

POWER

USAGE

WD-73C11 V45C 43.6" 65.0" 17.5" 77.9 lbs 260W

WD-73640 V45 43.6" 65.0" 17.5" 77.9 lbs 260W

WD-73CA1 V45CA 43.6" 65.0" 17.5" 77.9 lbs 270W

WD-73740 V45+ 43.6" 65.0" 17.5" 77.9 lbs 270W

WD-82740 V45+ 48.7" 73.3" 19.8" 129.9 lbs 270W

WD-82CB1 V45CB 48.7" 73.3" 19.8" 129.9 lbs 270W

WD-73840 V45++ 43.6" 65.2" 17.5" 83.6 lbs 290W

WD-82840 V45++ 48.7" 73.2" 19.8" 133.6 lbs 275W

WD-92840 V45++ 54.8" 82.1" 22.0" 195.1 lbs 290W

Page 6

MODELS: WD-73640 / WD-73740 / WD-73840 / WD-73C11 / WD-73CA1 /

WD-82740 / WD-82840 / WD-82CB1 / WD-92840

Version 3.0

SAFETY PRECAUTIONS

NOTICE:

Observe all cautions and safety related notes located inside the receiver cabinet and on the receiver chassis.

WARNING:

1. Operation of this receiver outside the cabinet or with the cover removed presents a shock hazard from the

receiver's power supplies. Work on the receiver should not be attempted by anyone who is not thoroughly

familiar with the precautions necessary when working on high voltage equipment.

2. When service is required, observe the original lead dress. Where a short-circuit has occurred, replace those

components that indicate evidence of overheating.

SAFETY PRECAUTION

To protect your eyes, do not look directly into the lamp, or light coming directly from the lamp, lens or

mirror.

Leakage current check

Before returning the receiver to the customer, it is recommended that leakage current be measured according to the

following methods.

1. Cold Check

With the alternating current (AC) plug removed from the AC source, place a jumper across the two AC plug

prongs. Connect one lead of an ohm meter to the AC plug and touch the other lead to each exposed metal

part (i.e. antennas, handle bracket, metal cabinet, screw heads, metal overlay, control shafts, etc.), particularly

any exposed metal part that has a return path to the chassis. The resistance of the exposed metal parts hav-

ing a return path to the chassis should be a minimum of 1Meg Ohm. Any resistance below this value indi-

cates an abnormal condition and requires corrective action.

2. Hot Check ...Use the circuit shown below to perform the hot check test.

1. Keep switch S1 open and connect the receiver to the measuring circuit. Immediately after connection,

and with the switching devices of the receiver in their operating positions, measure the leakage current

for both positions of switch S2.

2. Close switch S1, energizing the receiver. Immediately after closing switch S1, and with the switching

devices of the receiver in their operating positions, measure the leakage current for both positions of

switch S2. Repeat the current measurements of items 1 and 2 after the receiver has reached thermal

stabilization. The leakage current must not exceed 0.5 milliampere (mA).

GWG - Green Wire Ground

(Earth Ground)

S2

S1

OPEN

GROUND

SUPPLY CONNECTOR GROUND

RECEIVER

INSULATED TABLE

TOUCH ALL

EXPOSED

METAL PARTS

AC MA

METER

L

N

Page 7

MODELS: WD-73640 / WD-73740 / WD-73840 / WD-73C11 / WD-73CA1 /

WD-82740 / WD-82840 / WD-82CB1 / WD-92840

Version 3.0

DISASSEMBLY & PARTS REPLACEMENT

BACK COVER REMOVAL

Back Cover Removal

1. Remove screws (A) and remove the Lamp Cover.

2. Remove screws (B) from behind the Lamp Cover.

3. Remove Screws (C).

4. Remove the back cover from the TV.

C

A

ASSEMBLY LOCATIONS

CHASSIS

OPTICAL ENGINE ASSEMBLY

DMD FAN LAMP PWB-BALLAST

B

C

Page 8

MODELS: WD-73640 / WD-73740 / WD-73840 / WD-73C11 / WD-73CA1 /

WD-82740 / WD-82840 / WD-82CB1 / WD-92840

Version 3.0

PWB-SOUND

CONNECTORS

(ON REAR)

CHASSIS - REMOVAL & DISASSEMBLY

Chassis Removal

1. Remove screws (A).

2. Slide the chassis back and disconnect all cables.

3. Remove the chassis from the cabinet.

A

Rear Terminal Cover Removal (To Replace PWB-MAIN)

1. Remove nut (A) from the ANT input.

2. Remove screws (B) and (C).

3. Disconnect the connectors to the PWB-SOUND (V45++).

4. Remove the Terminal Cover from the chassis.

V45++ Only

C

V45++ Only

B

Page 9

MODELS: WD-73640 / WD-73740 / WD-73840 / WD-73C11 / WD-73CA1 /

WD-82740 / WD-82840 / WD-82CB1 / WD-92840

Version 3.0

PWB-POWER Removal

1. Disconnect all cables from the PWB-POWER.

2. Remove screws (A).

3. Pinch the Retainer to release the PWB.

4. Lift the PWB-POWER from the chassis.

A

PWB-MAIN Removal

1. Disconnect all cables to PWB-MAIN.

2. Remove screws (A) from the bottom of the PWB-MAIN.

3. Lift the PWB-MAIN from the chassis.

A

After PWB-MAIN Replacement

See Data Transfer in Service Procedures section.

1. V45C, V45 & V45CA: Perform “Restore Engine Data From Backup.”

2. V45+, V45++ & V45CB: Perform “Restore Engine Data From Backup” and “Restore Geometry Data From

Backup.”

V45+, V45++, V45CB IMPORTANT REPLACEMENT NOTE: If the customer has subscribed to VUDU (Internet

program provider), the customer must be instructed to contact VUDU to re-activate their account after the replace-

ment PWB has been installed. The original PWB cannot

be installed in another TV. It must be returned to Mitsu-

bishi per policy.

Retainer

(Pinch)

A

Page 10

MODELS: WD-73640 / WD-73740 / WD-73840 / WD-73C11 / WD-73CA1 /

WD-82740 / WD-82840 / WD-82CB1 / WD-92840

Version 3.0

OPTICAL ENGINE ASSEMBLY - REMOVAL & DISASSEMBLY

Note: To remove the PWB-BALLAST, it is not necessary to remove the Engine or Lamp Cartridge.

1. Release the Latch to lift the PWB-BALLAST up from the mounting bracket.

2. Slide the PWB-BALLAST out of the Engine Assembly.

3. Disconnect the electrical locking connectors indicated.

4. To reinstall, first connect the connectors. Then slide the PWB under the Retaining Hooks. Then press the rear

edge of the PWB down onto the guide pins to engage the latch.

LATCH

CJ1 (Lamp Power)

CJ3 (Lamp Control)

CJ4 (HV to Lamp)

RETAINING

HOOKS

PWB-BALLAST REMOVAL

PL (Lamp Power)

OPTICAL ENGINE ASSEMBLY REMOVAL

1. Disconnect the PL connector from the side of the PWB-POWER.

2. Disconnect the FB connector from the side of the PWB-MAIN.

3. Loosen the wiring harnesses from the looms.

FB

(Lamp Control and Lamp Door Switch)

Page 11

MODELS: WD-73640 / WD-73740 / WD-73840 / WD-73C11 / WD-73CA1 /

WD-82740 / WD-82840 / WD-82CB1 / WD-92840

Version 3.0

A

J12 (LVDS)

PE

(Engine Power)

OPTICAL ENGINE ASSEMBLY - Disassembly

1. Loosen screw (A) to remove the Lamp Cartridge.

2. Remove screws (B) and the lamp top cover.

3. Remove screws (C) and the Engine Plate

4. Disconnect the Exhaust and Sirocco Fan Connectors (J4 and J8) from the back of the Engine and loosen the

wiring harnesses from the looms.

5. Release the Latches to remove the Fan Holder.

B

J4

(Exhaust Fan)

LATCH

J8

(Sirocco Fan)

LATCH

OPTICAL ENGINE ASSEMBLY REMOVAL (Continued)

1. Disconnect the PE and J12 connectors from the Engine.

2. Remove screws (A).

3. Slide the Engine Assembly back out of the cabinet.

A

FAN HOLDER

C

ENGINE PLATE

C

Page 12

MODELS: WD-73640 / WD-73740 / WD-73840 / WD-73C11 / WD-73CA1 /

WD-82740 / WD-82840 / WD-82CB1 / WD-92840

Version 3.0

Duct Interior Components

Duct Interior Components are shown below.

Notes:

 When replacing the Optical Engine, transfer all Duct and Duct Interior Components from the old Engine to the

new Engine.

 The Exhaust Fan must be installed so the Label is facing inside the Duct.

 The Sirocco Fan must be installed so the Label is facing up with the Flanges aligned onto the Guide Pins.

SIROCCO FAN

(Label Facing Up)

(Label Facing In)

EXHAUST FAN

PWB-LAMP DOOR SW

Sirocco Fan Flanges

Align Onto Guide Pins

Page 13

MODELS: WD-73640 / WD-73740 / WD-73840 / WD-73C11 / WD-73CA1 /

WD-82740 / WD-82840 / WD-82CB1 / WD-92840

Version 3.0

LOWER DUCT

Lower Duct Removal

1. Remove the Lamp Cartridge, Top Cover, Exhaust Fan and Sirocco Fan.

2. Disconnect the HV Lamp Wiring from the Ballast and loosen it from the guides.

3. Remove screw (A) on the rear of the lower duct.

4. Carefully remove the Lower Duct from the Engine.

OPTICAL ENGINE REPLACEMENT

1. Install Lower Duct and components on the new Engine.

2. Connect the HV Lamp Wiring to the Ballast and dress the wiring through the guides as shown.

3. Remove the Protective Lens Cover from the face of the Lens and place it on the old Engine for return.

4. Install the Engine Assembly in the cabinet.

5. Perform the following procedures as described in the Data Transfer section of the Service Procedures:

 “Restore Index Delay”

 “Save Engine and Geometry Setting to Backup”

6. As necessary, perform the Horizontal and Vertical Centering Adjustment and Manual Geometry Alignment as

described in the Service Adjustments section of the Service Procedures.

A

HV LAMP WIRING

Dress Through Guides as Shown

Add VINAL CLAMP at center Guide.

Page 14

MODELS: WD-73640 / WD-73740 / WD-73840 / WD-73C11 / WD-73CA1 /

WD-82740 / WD-82840 / WD-82CB1 / WD-92840

Version 3.0

PROJECTION LENS REPLACEMENT

CAUTION: Any dust or fingerprints in the optics can cause abnormalities in the picture.

This procedure should be performed in a dust free environment.

Wear lint free cotton or rubber gloves while performing this procedure.

1. Remove Optical Engine Assembly.

2. Remove screw (A) and remove the Lens Collar.

3. Remove screws (B).

4. Lift out the Projection Lens.

5. Install the replacement lens so the key is oriented towards the top as shown.

KEY

LENS

B

LENS

COLLAR

A

Page 15

MODELS: WD-73640 / WD-73740 / WD-73840 / WD-73C11 / WD-73CA1 /

WD-82740 / WD-82840 / WD-82CB1 / WD-92840

Version 3.0

CAUTION: This procedure should be performed in a dust free environment.

Any dust entering into the optical compartment can cause abnormalities in the picture.

1. Remove the Optical Engine Assembly.

2. Remove the Lens Collar and cover the projection lens to protect it from scratches. See previous page.

3. Disconnect the 2 connectors, J6 & J7, from the front side of the Light Engine. Note the orientation of the

ribbon cable for re-assembly (Silver Contacts towards the Lens).

4. Access the optical compartment by removing screws (A) and the Engine Base from the bottom of the Opti-

cal Engine

5. Remove the 3 screws (B) from the Color Wheel Assembly.

6. Use the metal Handle to lift the Color Wheel from the compartment.

7. For installation, reverse the procedure above.

CAUTION: Avoid touching or scratching the Color Wheel.

8. After re-assembly, perform the Index Delay Adjustment described in the

Service Adjustments section.

IMPORTANT: If part return is required, prevent damage by packing the

color wheel the same way the replacement part was sent to you.

ENGINE BASE

COLOR WHEEL REPLACEMENT

J6 & J7

(Opposite Side of Formatter PWB)

LENS COLLAR

B

HANDLE

A

Page 16

MODELS: WD-73640 / WD-73740 / WD-73840 / WD-73C11 / WD-73CA1 /

WD-82740 / WD-82840 / WD-82CB1 / WD-92840

Version 3.0

SCREEN REPLACEMENT 73” Models

Screen Assembly Removal and Replacement

1. V45C, V45, V45+ - Remove the Screw Caps to access screws (A).

2. V45++ - Remove the ORNAMENT LEFT & RIGHT first by pinching up and pulling away from the bottom.

Then remove the ORNAMENT CENTER using the same method.

3. Remove screws (A).

4. Remove screws (B) around the rear edge of the screen bezel.

5. During re-assembly replace screws in their original locations.

B

73 INCH

V45++ (73”)

ORNAMENT

CENTER

(Speaker Cover)

ORNAMENT RIGHT ORNAMENT LEFT

A A A

V45C,V45, V45+ (73”)

A

Number and Location of

Screws Varies by Model

Page 17

MODELS: WD-73640 / WD-73740 / WD-73840 / WD-73C11 / WD-73CA1 /

WD-82740 / WD-82840 / WD-82CB1 / WD-92840

Version 3.0

A

73 INCH

(Rear View)

Screen Removal From the Bezel-Front

1) Remove screws (A) and remove the top, bottom and side rails.

NOTE: The number and location of screws vary by model.

2) Lift the Fresnel Lens and Lenticular screen from the Bezel-Front.

3) During re-assembly replace screws in their original locations.

SCREEN REPLACEMENT 73” Models (continued)

Example Diagrams. The number and location of screws varies by model.

Page 18

MODELS: WD-73640 / WD-73740 / WD-73840 / WD-73C11 / WD-73CA1 /

WD-82740 / WD-82840 / WD-82CB1 / WD-92840

Version 3.0

SCREEN REPLACEMENT 73” Models (continued)

CAUTION: Wear gloves when handling the Lenticular Screen and Fresnel Lens.

This prevents cuts and finger prints. Do not place Fresnel Lens in the sun.

This may cause fire and heat related injuries.

Lenticular Screen and Fresnel Lens Removal

1. After removing the top, bottom and side HOLDER-SCREEN rails and their cushions from the Bezel, lift the

screens as a single unit from the frame.

2. Separate the Lenticular Screen and Fresnel Lens.

Note: When separating the Lenticular Screen from the Fresnel Lens, use caution

while prying the Screen and Lens apart. Use a slot type screw driver, and

remove the pressure sensitive double sided tape.

Lenticular Screen and Fresnel Lens Replacement

1. Apply LENS-TAPE along the rear top edge of the Lenticular Screen.

2. Place the Fresnel Lens on top of the Lenticular Screen, and apply pressure along the top edge.

3. Place the screens in the screen frame and reinstall the cushions, top, bottom and side rails.

NOTE: The Lenticular Screen label must face the front and the Fresnel Lens label face the rear.

4. Reverse the Screen Removal Procedure and insert the screens in the Bezel.

BEZEL FRONT

LENS-TAPE

SCREEN

LENTICULAR

LENS

FRESNEL

COVER-HOLDER-T

HOLDER-SCREEN-S

HOLDER-SCREEN-B

LABEL

HOLDER-SCREEN-T

SPACER-SCREEN-S

SPACER-SCREEN-B

SPACER-SCREEN-T

Page 19

MODELS: WD-73640 / WD-73740 / WD-73840 / WD-73C11 / WD-73CA1 /

WD-82740 / WD-82840 / WD-82CB1 / WD-92840

Version 3.0

B

A A

SCREEN REPLACEMENT 82” & 92” Models

Screen Assembly Removal

1. Remove screws (A) around the bottom rear edge.

2. (V45+) Remove the Pedestal cover and remove screws (B).

3. (V45++) Pull off ornamental Front Covers and Speaker Grill.

4. Remove the Speaker Box and Pedestal by removing screws (B).

5. Remove screws (C) from the bottom front of the screen assembly.

6. Remove screws (D) from the top rear edge of the cabinet.

NOTE: Leave one screw secured at the top. Then support the assembly to prevent it from falling while

removing the remaining screw.

B

D D D

C

A A

SPEAKERBOX

B

PEDESTAL

V45++

WD-82840

WD-92840

PEDESTAL

V45+

WD-82740

WD-82CB1

Page 20

MODELS: WD-73640 / WD-73740 / WD-73840 / WD-73C11 / WD-73CA1 /

WD-82740 / WD-82840 / WD-82CB1 / WD-92840

Version 3.0

SCREEN REPLACEMENT 82” & 92” Models (continued)

CAUTION: Wear gloves when handling the Lenticular Screen and Fresnel Lens.

This prevents cuts and finger prints. Do not place Fresnel Lens in the sun.

This may cause fire and heat related injuries.

Lenticular Screen and Fresnel Lens Removal

1. Remove four screws (A) in all four corners of the Screen Bezel.

2. Remove the Screen Bezel components from the Screen/Lens Assembly.

A X4

CORNER-S-T

CORNER

COVER-HOLDER-T

CORNER-CAP

S-L

FRONT

SCREEN/LENS

ASSEMBLY

CORNER-S-T

HOLDER-SCREEN

TOP-R

CORNER-CAP

TOP-L

LABEL

S-R

HOLDER-SCREEN

B-L

CORNER

B-R

HOLDER-SCREEN-B

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